Production of metallic aluminum from impure materials



April 2 1, 1925.

W.' HOOPES ET AL PRODUCTION oF METALLIQ ALUMINUM FRM IMPURE MATERIALS Filed Dec. 21, 1922 2 sheets-sheet 1 WN @N MN 35D gw Patented Apr. 21; 192s.

UNITED STATES PATENT orrlcE.`

WILLIAM Hoorns, or PITTSBURGH, AND FRANCIS c. RRARY AND JUNIUs D. ED-

wenns, or oAxMoNT, PENNSYLVANIA. AssIcNoRs To ALUMINUM coMraNY or AMERIcA, or PITTSBURGH, PENNSYLVANIA, A coRroRATIoN or rRNNsYLvANu.

PRODUCTION OF METALLIC ALUMINUM FROM IMPUBE MATERIALS.

' Application :nea December 21, 1922. serial No. 608,283.

" To all whom it may concern:

Be it lcnown that we, WILLIAM HoorEs, FRANCIS C. FRARY, and JUNIUS D. EDWARDS, all citizens of the United States of America,

5 the said l/VILLTAM Hoorns residing at Pittsburgh and the said` FRANCIS C.. FRARY and JUNIUs D. EDWARDS residing at Oakmont, all in the' county oit-Allegheny and State ot' Pennsylvania, haveinvented certain new and l useful Improvements in Production lot' Metallic Aluminum from Impure Materials, of which the following is afull, clear, and exact description.

This invention relates to the production l of metallic aluminum of practically any high degree of purity, from all naturally occurring materials containing substantial amounts of'alumina, as for example, bauxite, feldspar, .common clay, alunite, Wavellite, etc.

The chief object of the invention is to provide for the purpose mentioned a processv which is commercially practicable in respect to the cost of the aluminum produced. Another ,object is .to provide a process in which pure alumina, purecarbon anodes, or other pure materials or products are not, in

general, required in any stage or step.' All naturally occurring aluminous materials contain impurities in substantial amounts, as

:zo for example iron', titanium, and silicon, and

must be carefully purified by costly chemi- 4cal means to tit them for use in prior methods ot producing aluminum; and accordingly another object ot the present invention is aa to provide aprocess by which pure aluminum can be obtained without preliminary chemical treatment to remove impurities such as those referred to. Still another important object is to provide a process of producing 4o aluminum, in which fravr materials once heute-fl need not be allowed to cool, with the attendantloss ot heat, until they are-converted into the liuislied product ofthe process, and in which the costoi' transporting 15 and storingr large amounts of costly intermediate products or materials, such as the ure alumina required for prior processes, is eliminated.

In carrying outthe invention in the preferred manner the aluminous material may be treated to remove 'more or less of any iron and titanium contained in it and to produce from the material a commerciall usable iron-silicon alloy and a highly a uminous residue or slag containing the greater part ot' the alumina. This residue or.slag may, and preferably does, contain some silica, and it is not necessaril entirely free of iron or titanium. On t e contrary it usually contains small amounts of one or both of these elements, but their presence is allowable up to several per cent.

The slag described above is now treated with carbonaceous or other suitable reducing agent, in the presence of copper and at anvelevated temperature, to reduce alumina and silica and cause the resulting impure aluminum and silicon to be absorbed by the copper, thus giving an impure aluminumcopper alloy containing silicon.- Here again the presence of small amounts of liron and titanium in the product ispermissible.

there it is desired to produce an aluminum-copper-silicon alloy containing more than a small percentage' of silicon, 1t may, 1n some cases, be better to add the eXtra silicon later. AThis may bedone advantageously by producing, in 4a separate furnace, an alloy containing copper 4and silicon, rich in the latter ingredient,and blending a sutllcient amount of this alloy with the alloy of lower silicon content produced as outlined above. In'most instances ,it is desirable to have the silicon-rich alloy contain aluminum. Where material. is available which is already vsufficiently low inA iron and titanium, as in the case ot' certain White bauxites or the residue from the calcination of alunite, it may not be necessary to subject the material to treatment designed particularlyl for the removal .of iron and titanium; in which case the aluminum-copper-silicon allo can be produced by 'direct reduction o the material, with or without the addition of" silicon in suitable term, as above described. On the other hand, in the case of materials of sufficiently low iron content but containing toov much titanium, as for example certain White bauxitcs, a suitable aluminum-copper-silicon alloy can be produced therefrom directly, as by clectrothermal reduction in the presence of copper, and thereafter removing titanium by allowing it to separate out in the form of dross which is removed by skimming. In this method .of removing titanium the alloy should-be removed from the furnace at a temperature high enzu h to insure that the titanium is carried wit it. The alloyl is -then cooleddownto a suitable temperature, say somewhat below about 1000 C. but substantially above the freezing point of the main -body of the alloy.. Dur- 1n `this cooling most of the titanium,'or a su stantial amount of it, separates out 'in the form of dross, as already stated. Not? withstanding" this treatment the alloy may still contain an undersirable amount ofim` pur1t1es,. probably non-metallic in character.

If this is found to be the` case, such impur-A ities as are mechanically entrapped or suspendedA in the allo can be decreased tothe desired extent by'\ urther treatment, for ex- .ample as described hereinafter.

from, so that the alloy, which constitutes the v anode`,gwill remain in the'bottom of the cell the electrolyte will float' on vthe alloy, and

the pure aluminum, ywhich forms the cathode, will -iioat on the electrolyte, throughout -a wide range of workingtemperatures. This ste removes aluminumifrom the anode alloy an deposits it on the cathode aluminum,

leaving behind, in the alloy, practiallyall" the copper, silicon, iron and other 1mpurities, except to the extent that one or more of these substances, as for example silicon, may be desired 1n, or is unob]ect1on able m, the cathode alumlnum.

When the aluminum (or the desired por tion'of it) has been removed from the anode alloy the latter, thus impoverished of. aluminum, is withdrawn from the electrolytic cell andqmay be treated to remove more or less silicon, iron and titanium, being'sub-v sequently returned tothe second step of the process for re-use in` making the needed aluminum-copper alloy. Theutreatment of the'residu'al improverished alloy to diminish its -impurity content may consist in a simple oxidation and slagging in the well known wa v gy the process outlined above it has beenpossibleto produce on a commercial scale, from common bauxite, -or even from clay,

aluminum having a purity of over 99.8 per ,y

silicon alloy are effected may be carried on cent; and that, too, at a cost materially lower than the cost of producing aluminum by the Hall process, wh1ch. ,at`best, using materials carefully purified in advance, gives a product of less purity.

'the alloy or crude aluminum produced by the preceding steps; and

Fig. 4 is a diagrammatic sectional view illustrating an apparatus suitable for the step in which the residual copper is prepared for r e-use in the process.

As will be seen from Fig. 1, the first ste of the process (as performed-in the preferred manner) comprises'I smeltingy material containing alumina and silica and iron and titanium oxids, tol produce erro-'silicon and a. highly aluminous slag containing alumina and silica, but with limited amounts of iron andl titanium. The `ferro-siliconandthe slag ,may be` withdrawn separately, the former fon-use in steel making'or for other purposes and 'the latter for` ,treatment in the second step, whereA it 'is smelted in step 2 (with or without additional silica) in the presence of copper to produce 'aluminumcopper-silicon alloy of low iron and titanium content. 'Any unreduced slag or dross produced in thisl step 'maybe returned to the' furnace, while the aluminum-copper-silicon alloy isl withdrawn and (after reparatory' purifying if necessarytor desira le, as step 2, for example) -is subjected 'toelectrolytic treatment in step 3, where the aluminum isr removed. The residual alloy, containing the copper, and Asuch lamount of theotier ingredients as hasnotbcen allowedto be deposited with the aluminum, is withdrawn and may be ltreated in step 4 to remove enough'of theseother ingredients to leave the'copper :lit for re-use in ste 2. Thus the copper can bezusedl repeated y, circulating through steps 2, 3 and 4 as a vehicle for the aluminum. lin cases where the impurity content of tlie'residual alloy is nottoo hi h the alloy can go back to step 2 directly, wit 1- out preliminary puricationg' The process thus outlined will now be described in detail,

with the understanding, however, that many R of the details, though advantageous and in -some cases important, are not in all cases indicated at 15.

. The energy successively or simultaneously in separate electric furnaces. For these steps, furnaces of the type illustrated in Fig. 2 are suitable and advantageous. In the figurereferred to, 1() designates an' openitoppe'dsteel shell of upright cylindrical form, contalnmg a carbon bottom 11 and a refractory side lining 12 composed of fire-brick, bauxite-brick or other suitable material. The carbon`bottom slopestoward a tap hole 13 for withdrawing ferro-silicon or aluminmn-coppersilicon alloy, as the case may be. A tap hole 14 at a higher level permits withdrawal of slag independently of the underlying alloy. All these` openings may be closed in any convenient manner. For example, a plug of pine wood maybe driven into the hole, as The heat encountered causes the plug to burst into iame immediately and it is converted into charcoal in a' few minutes, but it lasts long enough to Astop the -flow of metal or slag and permit solidification back of the plug. The spout 16,l preferably rather steep so as to prevent clogging by freezing due to rapidcooling of the slag or-metal, may be lmed with a -mixtu're Aof magnesite and ire clay moistened with a solution of water-glass.

Conducting members are embedded in the carbon bottom or lower electrode 11 forcennection with one terminal ofa source of alternating current represented by the transformer 17. Preferably the conducting members are in the Aform of steel pipes, as indicated at 18, through which water vmay be passed for cooling purposes. The upper electrode is a carbon cylinder 19, connected to" the other terminal of the secondary of the transformer 17. 4Any suitablemeans, no-t shown, maybe provided to raise and lower the -electrode and hold it in position. input can be regulated in any convenient way, for example by varying the .numbeu'of, ampere turns in the ltransformer,l preferably in the primary thereof,

as indicated by the adjustable primary ter l mlnal 20.

The furnace may be'ycooled, if necessary 'lor desirable, by water discharged upon the outer shell from an encircling pipe 21, arranged at the upper partof the' shell and connected to-a source of supply, not shown. The water running down the shell can be caught *byv a. trough 22 and carried away by Y a drain pipe 23. To keep water out ofthe f tap holes the latter may l suitable shields, as 241 be provided with When it is used for producing ferro-silicon and 'the aluminousv slag, the furnace builds up a lining, as indicated at 25, for example, composed, especially in the lower part of the furnace, of charge and solidified' slag.

An electrolytic cell suitable for removing aluminum from the aluminum-copper-siliexternal water 'a rubber Aprecise number is immaterial.

-in any convenient manner,

two shell posed of refractory materialV having good thermal and electrical insulating `properties., The lining mentioned may be formed by the method described in the'copending application of William Hoopes, Junius I). Edwards, and Basil T.' Horseld,Serial N o. 608,289, filed December 21, 1922. According to the preferred manner of carrying out the method referred to, the lining is formed I by freezing a crust on the sides of the shell, from a molten mixture containing aluminum, sodium and barium fluorids, and alumina suflicient inI amount to saturate.- the mixture, so thatY the alumina freezes out, in in fine crystalline corundum-like form. A lining crust of this type has a relatively high melting point` and hence will remain solid in the'operation of thecell unless the temperature therein becomesfabnormally high. To aid in keeping the crust solid and maintain the desired electrical insulating properties the cell is provided with jackets 35, 36,4 connected by pipe 37. Cooling water issupplied to the lower` jacket` through arubber pipe 38 and is carried from the upper jacket by a rubberpipe 39. In the edge of the upper shell section isa tapping notch 40, for withdrawal of the refined aluminum. This notch or opening is normally means of anyfsuitable refractory material, as for example bath material, which will not contaminate the metalwith which it comes in contact. Threeupperl electrodes, 41, are shown, but it will be understood that the They are connected to thev negative pole of a source of unidirectional current, represented ,convenl tionally at 42, by means of horizontal transverse busbars 4l to whichthe copper rods 41", attached to the electrodes, are secured preferably so as to permit the electrodes to be raised and lowered individually. The carbon bottom 32 is connected-to the lower rbusbar 32, en-

circling the cell, by a series of embedded distributor plates of steel, spaced equidistantly minal of the source 42. The upper electrodes are preferably composed of graphite, as devdepression, and over the joint between the sections, 1s a side l1n1ng'34, coinclosed by scribed and claimed in the copending application of Francis C. Frary, SerialI No. ($72,867, filed November 5, 1923.

Our present invention is carried out preferably in the following manner.

As an example it is as sumed that clay is to be utilized as a source of aluminum` for example clay of about the following com-v position:

Per cent. Alumina (A1203) 38 Silica (SiO2) 55 Iron oxid (Fezn) 5 Titanium oxid (titanic acid, TOZ) 2 With the clay, preferably first calcined to eliminate moisture, iron is used in such amount that the total' iron content of the charge (including the iron of the clay) will be suffi-cient to-take up all ofthe reduced silicon and titanium, with the production of ferro-silicon containing, preferably, about 25vper cent ot' silicon. A reducing agent isne'eded, and for this purpose carbon, which may be iu the form of coke, is employed. The amount of reducing agent should be sufficient to reduce all of the titanic acid and most of the silica; and inasmuch as the carbon ot' the upper electrodes takes part in the reaction, rather less carbon is supplied with the charge than would otherwise be needed. It may also bel desirable to have some of the carbon in the form of charcoal, for the purpose of increasing the specific resistance of the charge. The iron component may be metallic but is preferably in the form of an ore, say Fe203. For the purpose of making the aluminous residue or slag more fluid there may be added a little luxing material, for example feldspar, soda ash, common salt, or, preferably magnesia, as explained in the copendingapplication of Frank D. Shumaker, deceased, VSerial N o. 623,370, filed March 7 1923. The,quantitative composition of the charge or mixture is dis-A cussed hereinafter. y

In starting the process in. the preferred manner the bottom of the furnace is covered with a layer of crushed coke, the electrode is lowered into contact with the coke, and the current is turned on.` The electrode is then raised slightly, resulting in the formation of arcs and causing heating of the furnace interior. The. charge is then delivered to the furnace. When the temperature has increased sufficient-ly the reaction begins, reducing the iron,V silicon, and titanium oxids, and producing a mixture of the corresponding elements, which mixture as fermsilicon-titanium alloy sinks to the bottom, whence it is withdrawn from time to time through the tap hole 13. In the drawing the molten alloy is indicated by the layer 26.

The quantitative composition of the charge mixture depends in large measure upon the alloy and slag which are to be produced. Suppose, for example, that with a clay of about the analysis above given, ferro-silicon of about the following analysis is desired: iron,72 per cent; silicon, 25 per cent; aluminum, 2 per cent; titanium, l per cent. In such case the materials may be used in the proportions, approximately, of clay, 100 parts; carbon, 40 parts; iron, including the iron of the oxid in the clay, parts; magnesia, including that present in the clay, 3 parts. The components are crushed to pass through a one or one. and a half inch screen, and after they have been thoroughly comn'ilngled the mixture is charged into the furnace as required. 4 0f the components of the charge, the iron and silicon oxids can be reduced more easily than titanium oxid, and the latter more easily than alumina and magnesia; and accordingly there remain unreduced a small portion of the silica, the major portion of the alumina, and all or substantially all of the magnesia.. These unreduced materials float in the form of slag on the ferro-silicontitanium alloy.

The ferro-silicon titanium alloy, which may or may not contain a small amount of aluminum, can be used in steel manufacture, its quality making it highly desirable for that purpose. The porportions of the three met-als named can be varied in a number of ways, as for example by changing the proportion of ironl in the charge, or by substituting more or less of the alloy itself for a portion of the iron in the charge so that the alloy is enriched in silicon and titanium by passing through the reaction zone of the furnace a second or third time.

The composition of the aluminous slag produced can be controlled in various ways, as for example by changing the temperature at which the reaction takes place, which may be done by varying the rate of energy input or the amount of magnesia or other flux used, or both. Another method is to vary the length of time during which the slag is allowed to remain in the reaction zone. By using an excessive quantity of iuxing material it is possible to produce a. slag of such low melting point that the entire charge melts down at al temper-attire below the reaction temperature, so that little or no reduction of silica and titanium` oxid takes place. By varying the amount of' flux themelting point of the slag can be varied within wide limits. It is found in practice, however, that it is desirable to have the melting point of the slag only slightly lower than the lowest desired react-ion temperature, which, in producing ferro-silicon, is in the neighborhood of 16000 C. A' slag of such'melting point is suiciently fluid to cir- 'culate freely at the reaction 4temperature and promote the carrying on of the reactions without causing such rapid melting of the charge as to render attainment of the desired temperature in the reaction zone diiiicult or impossible. Using a charge of the composition previously given herein,and producing a ferro-silicon-titanium alloy ofthe c0m position stated, the slag produced is oiiabout the followin g analysis: alumina, 88 per cent; silica` 3 per cent; iron and,titan1um,ilj1ess than 2 per cent; magnesia, 7 per cent. The materials employed for the produc-l tion of aluminum-copperfsilicon alloy in the second step of the process are the aluminous slag produced in the iirst step; 'carbon, preferably in the form of ke'gend finely divided copper, copper scale, or siliconcopper alloy. If the slag itself does not contain enough silica, a suitable amount of substantially iron-free silica-bearing material (china. clay, or clean sand, for eX- ample) may be added. Or the aluminumcopper alloy produced may be enriched with silicon by adding silicon separately; or by adding an alloy containing copper and silicon, produced in any vsuitable manner. The amounts of the materials used with Vthe the alloy to be produced, .and will be eX- plained more fully hereinafter. It will be sufficient here to assume that enough carbonaceous reducing agent is used to reduce 4substantially all the `-`silica 'and alumina.

The aluminum-copper alloy furnace may be like that shown in Fig. 2, and may be put into operation in the same manner.

Ordinarily most of the magnesia usedas iuxing agent is lost by reduction and vaporiz-ation in step 2. If desired the vapors from this step can be treated to recover any mag-l nesium, copper, and other valuable materials that they may contain.

The amount of aluminum that can be held by the molten copper depends largely upon thel temperature,since the higher the temperature, the higher the vapor pressure of the aluminum and hence the smaller will be the proportion ofv it that can be held by the copper. The absorption of aluminum by the copper is facilitated by the boiling action in the furnace, by which molten alloy is thrown up into thereaction zone Where it canmore readily absorb the aluminum` vapors generated there by the reaction.

- As previously stated, the lamounts of carbon and copper needed in the second step depend, in general, upon the composition of the aluminum-copper-Silicon alloy which is to be produced, as well as upon theamounts of alumina and silica or silicon provided (in the slag and from' other sources) to lsupply the aluminum and silicon. Accordingly the carbon and copper requirements can be vreadily determined, with all necessary accucontains, approximately, alumina, 88 per cent; silica, 3 per cent; and iron and titanium together, less than 2 per cent. In such case, with about 100 parts of the slag and 23 parts of additional sand, by weight, there Will be needed, roughly, parts of copper or 91 parts of copper oxid, and 46 parts of carbon. Instead of adding sand to furnish the 'additional silion needed, the latter can be supplied as such, or in an alloy of copper from any convenient and suitable source. The residual anode alloy from the electrolytie refining step of the process may be used for this purpose, if desired.

The reactions which take place in the above steps are believed to be the following:

In the production of the ferro-silicontitanium alloy- (1) SiOz-l-QGzSi-I-2C() (2) TiOz-i-2CzTi-I-2CO In the production 0f the aluminum-cop per-silicon alloy- (7) CuO-t-COzCu-t-CO2 If reaction (4) takes place it would appear that most of the aluminum so prosecondary reaction between the aluminum and the silica of the slag, since very little aluminum is ordinarily found in the ferrosilicon-titanium alloy; a result which, is highly davantageous in cases where it is desired to have as little aluminum as possible vin the alloy named. Of course reaction (7) takes place only when CuO is present.

In the copper-silicon-aluminum alloy the ratio of aluminum to copper should, in general, be as high as practicable, in order that a minimum amount of copper shall have to be circulated through the subsequent reiining and copper-recovery operations. The amount of aluminum which can be taken up by the copper is dependent upon the temperature at the reaction zone. .The minimum reduction temperature is so high (nearly 1800o C.) that the metallic aluminum has a high vapor pressure, and, of course, a still higher vapor pressure at the temperatures which must be maintained in order to carry on thereactions rapidly, that is, temperatures ranging from 1900 C. 11pward. For these reasons it is diiicult if not impossible to produce pure aluminum by direct thermal reduction of aluminous compounds by carbon. The aluminum resulting from that reaction is in vapor form; and at temperatures low enough to condense the vapor it rapidly reacts with the carbon monoxid present to form alumina and carbon, for which reason little or no aluminum lect at the bottom only when the respective proportions of aluminum and silicon contained are low enough so that the density of the alloy is in each case Agreater than the density of the slag with which itis in contact. For practical operation there should be a substantial dierence between the density of the slag and the density of the alloy'in order to secure eective separation of slag from alloy. In the case of ferrosilicon, reduction of the silica takes place freely at 1600o C. Its vapor pressure at temperatures well above this point is suiliciently low to permit this temperature to be exceeded considerably and still roduce silicon and have it absorbed by the iron, so that the limiting factor with regard to the proportion of silicon which will appear in the alloy is not so much the temperature prevailing as it is lthe relative densities of the ferro-silicon and the slag at the working temperature. With a heavy aluminum sla containing about 90 per cent alumina an 8 per cent or 9 per cent magnesia, an alloy containing more than 30 per cent silicon does not freely settle out of the slag so that it can be tapped from the bottom. Consequently, ferro-silicon containing about 30 per cent of silicon is about the highest that can be made in a reaction zone in which the slag is as above described.

In the production of ferro-silicon voltages between 30 and 8O volts have been found satisfactory, but in some cases a voltage as high as 125 may be used. For handling the preferred mixture, however, we

have found voltages in the neighborhood of.

60 to 70 to be preferable.

When producing the aluminum-copper alloys, we have worked with voltages between 30 and 60 volts, preferably about 40.

With regard to the current used, the amount is limited by the size of the electrode and its consequent ability to carry the cur- `Hall process, with carbon anodes.

rent without injury to itself and with good results in the reaction zone. The largest electrodes commercially made for use in furnaces of this type are 32-inch, which Work very well with currents` far above 20,000 amperes. With a 12-inch electrode, we use about 4,500 amperes as the maximum it will safely carry in the furnace without too rapid deterioration due to oxidation and other causes.

It has been found that the aluminumcopper-silicon alloy as tapped from the reducing furnace is not always suitable for immediate treatment in the electrolytic retining cell, by reason of the presence `of nonmetallic substances, such as carbon,alumina,

aluminum carbid, etc., or insoluble niaterials, such as compounds containing titanium, which clog the bath ofthe reining cell. Accordingly it is advantageous rate out in the form of dross, which can be skimmed ofi and returnedV to the step in which the alloy is produced. Another method is to allow the alloy to solidify. In general the latter method seemsl to give a more nearly complete removal. but it has the disadvantage of requiring the alloy to be re-melted. In either case a large part of the objectionable substances remaining in the partially cleaned alloy can, if necessary, be removed by a sort of electrolytic treatment in the molten state with a fused bath in a cell of the type ordinarily used in Ttic ie usual Hall cryolite-clectrolyte is employed, with the alloy as cathode, and the current is passed-through the cell for some time, say about two hours. The combination of the solvent eifect of the bath, thereducing effect of the current, and the additional opportunity afforded for mechanical separation of entrained solid particles,l results in the production of a clean alloy which may then be transferred to the electrolytic refining cell. The electrolytic cleaning or scavenging can be effected with alternatingy current but direct current is preferred. Any

suitable voltage and current density may be used, say 6 'to 10 volts, and about 800 to 1200 amperes per square foot of cross section ofl the bath.

In the electrolyticrefining step of the present process the aluminum-copper-Y silicon alloy produced as described above is used as anode, in contact with a superimposed layer of electrolyte or bath, pre-feruse as anode, shall be kept in a sufficiently mobile condition, in order that the aluminum contained in it shall'be free to continually replace, at the surface of the alloy, aluminum removed therefrom by the electrolysis. If aluminum is not kept continually present at the surface of the alloy, impurities in the latter may be re-dissolved and deposited at the cathode in such amount as to seriously aiiect the purity of the refined metal. Another feature of importance resides in promoting the secondary reactions by which impurities dissolved from the anode alloy are 're-precipitated thereon and those deposited on the cathode are 11e-dissolved in the bath; as for example by prodiicing an energetic circulation whereby the bath freelywashes,

or is freely washed by, the contiguous surfaces of the anode and cathode respectively. A further advantageous feature consists in maintaining at least a certain minimum proportion of aluminum in the anode alloy, as by withdrawing more or less of the latter and supplying fresh alloy in its place,'for the purpose of preserving the selective aluminum-dissolving action of the bath.

It is also important that the fused bath or electrolyte be used under such conditions that an adequate area of contact is maintained with the anode metal below and with the cathode metal above. Otherwise the composition of the bath or electrolyte will vary, a condition which has been found to be objectionable and in some cases fatal to success.

The electrolyte or bath which We prefer in the present method contains aluminum fluorid, with the addition of one or more fluorids of metals more electropositive than aluminum. Preferably the bath is ofv about the following composition z Percent.

, Aluminum fiuorid 25 to` 30 Barium fluorid l 30 to 38 Sodium fluorid 25 -to 30 Alumina 0.5 to 3 Calcium and magnesium fiuorids,

present as unavoidable impurities, about 2 The addition of fluorids of other of the alkali or alkali-earth metals is permissible. However, the presence of halogen yanions other than those of fluorin is undesirable,

and indeed is highly objectionable if aluminum of a high degree of purity is to be obis a desirable ingredient, but not, in general, in amount sufficient to saturate the mixture. The use of a bath containing barium uorid in amount between 20 and 60 per cent, or strontium fluorid 1n like amount, or

a mixture of the two, is claimed broadly in` our copending application Serial No. 608,-

285, filed December 2l, 1922. Barium and strontium arc alkali earth metals having atomic weights above 80. 4'

Speaking enerally, the bath or 'electrolyte employe `should be capable, under I ior-A mal conditions, of acting selectively with respect to aluminum, so that the latter can be dissolved from the anode alloy to the substantial exclusion of the other ingredients thereof. This important capability is possessed in high measure. by electrolytes of the class described in the foregoing.

A bath of a composition such as given above is fluid within the range of suitable working temperatures, and is of lower density than the impure aluminum or aluminuu'i alloy which has been found in general most desirable for the process. Hence the bath will float on the molten alloy. At the same time the bath is of higher density than the refined or purealuminum, so. that the lili' practice lies between 850 C. and 1100 Cl.,

approximately, with a preferred temperature of about 950 C. A bath of the analysis given above has at the preferred temperature mentioned a density of between about 2.5 and 2.7 grams per cc. Aluminum at the same temperature has a density of about 2.3 grams per Cc., and, 'if it contains only small quantities of heavy metals or even considerable quantities of silicon or other impurities of low density, will float on instead of sinking in the bath. The presence of about 25 per cent of copper gives an alloy mixture which at a temperature of 950 C. has a density of about 2.8. This is sufliciently above the density of the bath to insure that the alloy will not ioat but will remain at the bottom. A greater proportion of copper may be used, however, provided the freezing point of the alloy does not exceed the upperv limit of temperature for smooth working.

The freezing point ofl pure copper is around 1083o C., but the addition of 2 per ,which upper limit is between 1050o C. and

course, objectionable.

cent of siliconreduces the melting point to about 1050 C., and an alloy containing 82 per cent of copper and 18 per cent of silicon has a freezing point of about 815 C. Further additions of silicon have the effect of raising the' freezing point above this eutectic temperature, with the result that an alloy of 31 per cent silicon and 69 per centcopper has a freezing point of about 10500 C. Silicon is also effective in lowering the freezing point of an alloy of copper and aluminum. For example an aluminumcopper alloy corresponding in Composition to the formula CusAl (87.6% CWI-12.4% Al) has its freezing point lowered from about 1050 C. to about 930 C. by the addition of per cent of silicon. and to about 795 C. by the addition of per cent of silicon. The presence of silicon in amount between 2 per cent and 32l per cent of the copperplus-silicon therefore prevents the alloy from freezing at a temperature of 1050 C. or higher, and thus permits the removal of all or substantially all of the aluminum without causing the residual alloy to freeze at the temperature mentioned. The presence of iron and titanium, or either of them, tends to raise the freezing oint, which is, of ther materials than silicon will serve a like purpose of preventing the freezing of the alloy as the aluminum is removed, but silicon is preferred, and its cheapness permits it to be thrown away in the form of slag when the residual alloy is afterwards treated for recovery of the copper.` On the other hand, tin or other low-melting material miscible with aluminum land copper, would have to be thrown away, or would have to be recovered in the course of reclaiming the copper. In either case the net cost of the process would be increased. j

Aluminum has of itself the capability of lowering the freezing point of copper, and advantage may be taken of this fact, when necessary or desirable, by removing the alloy from the cell while it still contains some aluminum. In other words, the amount of aluminum and the amount of silicon should be so adjusted with respect to the other constituent or constituents that the anode metal` will at all times remain mobile within a range of working temperatures which will not cause objectionable alteration of the bath, as by volatilization of one or another of'its ingredients. Thus if it is desired to remove all of the aluminum, the silicon content when the aluminum has been removed should be not less than about 2 per cent of the co perplus-silicon; but if thel silicon content 1s not of itself sufficient to maintain the desired mobility, it may be necessary to remove the alloy (or replace a portion of it with fresh metal, or add silicon) before all the aluminum is extracted. Generally speaking there trained in the' anode alloy is not objectionable so long as it does not reduce the mobility of the alloy enough to prevent its free circulation and iow.

For the above reasons, the alloy previously described as a specific product of step 2 of the present process is well adaplted for electrolytic refining in step 3. T is 'alloy has aboutv the following composition:

Per cent Aluminum Copper 55 Silicon 8 Iron, less than 5 Titanium, less than 1 In the refining o eration the aluminum alloy or mixture o aluminum and otherv substances lies in molten form at the bottom of the cell as indicated at 46. Floating on this is a layer 47 of fused bath or electrolyte, and o n the latter is a layer 48 of molten aluminum, with the upper electrodes extending into it far-enough to insure good electrical contact, say an inch or two. The molten layers may be established in the cell kin any convenient manner, as for example by pouring the previously fused materials into place, using for the original aluminum layer the purest metal conveniently available.

Unidirectional or' continuous current is led into the anode alloy or impure aluminum and passes upward therefrom through the bath or electrolyte to the cathode above, with resulting deposition of aluminum thereat. High enough current density is used to make the resistance losses within the cell suicient to maintain the working temperature. Apparently the effect of the passage of the current is to set free iluorin or oxy en anions,

or both, in contact with the sur ace of the anode metal. The effect of the liberation of these anions is to dissolve, from the anode lao alloy, aluminum and any impurity present in the alloy which is more electropositive than aluminum and to leave behind the impurities which are less electropositive. Any of the latter impurities which may be attacked by the anlons tend to be immediately re-precipitated by a secondar reaction between the aluminum, with w ich they are in contact, and the fluorids or oxids of these less electropositive metals, with the result that only aluminum and impurities which are more electropositive pass into solution in the bath. 'In the anode alloy described above there are no impurities which Vare more electropositive than aluminum and therefore practically only aluminum goes into solution from this alloy, so long as the aluminum content remains relatively high and the aforesaid secondary reactions can occur freely.

With a bath containing sodium and barium fluorids there is also deposited at the cathode along with the aluminum, some barium and some sodium, the amounts being dependent, to some extent at least, upon the current density used and the quantitative\ composition of the bath; It has been found, howeveiythat both barium and sodium react, at the working temperature, with aluminum fluori to produce metallic aluminum and barium or sodium fluorid, as the case may be. Consequently so long as there is a sufciently high proportion of alumium fluorid in the bath, and the bat-h can freely wash the bottom of the cathode metal layer, no barium is found in the latter metal; but at the working temperature sodium, which is nearly insoluble in aluminum, is set free in gasseous form and small proportions of it escape before the secondary react-ion. can completely redissolve all of it.

-Hence minute traces of sodium are often found in the cathode metal, and some sodium escapes into the heat-insulating crust maintained above the top metal. rlhis quantity,

= however, is usually very small when the bath is kept in theproper condition of fusion and is not allowed to become deficient in aluminum iiuorid. Y i

Leading electrolyzing current to the anode and from the cathode in such manner that a magnetic field is produced in the cell, is considered tov be an advantageous feature. Thus in the apparatus illustrated the currents in the upper transverse horizontal busbars 41a and vertical electrodes 41, and in the lower encircling horizontal busbar 32a and tapering horizontal distributor orcollector plates B2b, produce in the cell a powerful and non-uniform magnetic field having both vertical and horizontal components. On account'of the relatively high specific resistance of the electrolyte, as compared with that of either the anode alloy or the top metal layer, the current density `throughout the horizontal cross section of the electrolyte and hence at its upper and lower surfaces, is substantially uniform. Likewise, the current density at the surface of contact between the conducting bottom lining and the anode alloy (which latter has much" better conductivity than the former) is substantially uniform, although the con*l ducting plates or ribs in the bottom liningv tend somewhat to concentrate the current. But in the anode alloy the current Hon' may have horizont-al as Well as vertical components, due in part tothe concentrating effect of the aforesaidplates in the bottom lining, and, probably, more especially, to the bowl-like receptacle in the bottom lining, whereby some of the current can iow between the anode alloy and the conducting side Walls of the receptacle. These horizon` tal components of current-now in the alloy are largely radial in direction. The interaction of the current liowing in the anode alloy and the non-uniform magnetic eld produced as explained above, causes the anode alloy (which, being molten, is in effect composed of movable conductors) to flow in various directions, and produces a powerful circulation and mixing of the alloy. The stirring thus produced is, we believe, an important factor in replenishing the active surface of the anode alloy with aluminum fast enough to satisfy the anions set free thereat, making possible more extensive removal of aluminum from the alloy or the use of a higher current density, or both, without depositing impurities at the cathode in such amount as to seriously affect its quality. Moreover, the interaction of currents and magnetic field in the bath and in the cathode produces a like stirring effect in these layers which is advantageous in promoting homogeneity of composition and temperature and especially in preventing the bath from being impoverished of aluminum at the surface in contact with the cathode. rlhe stirring effect described also insures intimate contact of the bath with the anode and cathode throughout their contiguous surfaces, thereby giving adequate opportunity for the secondary reactions by which elements (other than aluminum) deposited at the cathode are 11e-dissolved in the bath and by which im'- purities dissolved from, the anode are reprecipitated thereon.

The rening operation is continued until 7the desired amount of aluminum has been removed from the anode and added to the cathode.4 A portion of the top metal is then drawn off and the impoverished anode metal is withdrawn through the tap hole 49, fresh anode metal in the molten state being supplied in any convenient way, such that the refined metal fioating on the bath will not be contaminated. This operation may be conveniently performed by means of a carbon funnel, which, after being preheated, is let down until it nearly reaches the bottom of the cell, which has previously been cut out of the circuit. The refined metal entrapped in the funnel may be dipped out with av hand ladle, after which the fresh anode metal is poured in. The funnel is then lifted out. The fresh anode metal introduced is preferably suilicient in amount to raise the bath and top metal until the surface of the latter is at the saine level as before the withdrawal. l

The tapping out and replenishing operations may be repeated from time to time as necessary or desirable without seriously interrupting the refinin process.

Notwithstanding t e greater density of the bath, a portion of it is carried up by capillary action at the area of contact between the liquid aluminum and the vsolid boundary crust 34 and rises to the surface of the former, where it spreads in a thin layer, the weight of which is in'sufiicient to overcome the surface tension of the liquid aluminum. Consequently it spreads over the entire surface of the latter, and by reason of the escape of heat into the air, solidifies there in the form of a crust, as indicated, for eX- ample, ata. This process goes on until the resulting crust thickens so much that (the escapeofheat being thus retarded) the temperature of its under surface can rise to the melting point of the bath. When this thickness is attained, quantities of unsaturated bath subsequently carried up by capillary action can accumulate in liquid form under the crust and finally grow to a mass of sufficient dimensions to be able to sink through the aluminum. Hence if the bath is kept unsaturated with alumina the top crust forms up to a certain thickness, after which its growth ceases. On the other hand if the freezing point of the bath is raised by allowing it to become saturated, liquid bath finding its way to the under-surface of the crust solidifies there and increases the thickness. This action would, if unchecked, result eventually in bringing up a largefportion of the bath from below the aluminum and causing it to attach itself to the top crust. At the same time, the boundary crust at the sides of the cell thickens in the same manner, and the net result would ultimately be more or less complete solidification of the bath. For these reasons it is desirable to keep the bath unsaturated in the normal operation of refining.

The bath crust formed on the aluminum layer as above described serves as a convenient and good heat insulating medium to minimize loss of heat from the top of the cell, but it also cntraps sodium as already explained, with consequent increase of alumina in the bath. The amount of sodium which thus escapes from the bath can be minimized by using in the latter the highest permissible amount of aluminum fluorid.

Instead of forming the heat-insulating top crust in the manner hereinbefore specifically described, such a crust may be produced by dusting over the upper surface of the aluminum layer, soon after it is put in place, a layer of finely divided alumina, carbon, magnesia, or other suitable powdered material. This layer of finely divided material is rapidly cemented together by the liquid bath coming up from below and wetting it. The heat insulating property ofthe top crust may be increased by dusting any suitable powdered material over it after it has been formed, so that it is covered by a layer of such material, which is an excellent insulator by reason of its porous condition. Being supplied to the surface of the top crust after the latter has solidified, the additional heat-insulating materialis not cemented together and therefore retains its porosity. In general, the best material for the purpose is bath which has been allowed to solidify, since if any of it accidentally or incidentally finds its way below the top metal it does not contaminate the electrolyte. v

Several methods are available for keeping the alumina content of the bath below the saturation point. Fbr example the ltop metal (aluminum) can be ladled or tapped 0H' and a portion of the saturated or nearly saturated bath dipped out, liquid or solid alumina-free or (le-oxidized bath being added to take the place of that which was removed. The resulting mixture will then be well below the saturation point. Or a portion of the crust can be broken away and removed, whereupon the crust will re-form at the expense of the saturated bath within the cell, the excess alumina crystallizing out in corundum-like form. New aluminafree or de-oxidized bath can be added either in solid or liquid form to take the place of that which went to form the new crust. Tn the first method the saturated bath removed from the cell can be regenerated and prepared for re-entry into the process by crushing it and electrolyzing it in a separate pot for the reduction of the alumina, the deoxidized bath thus obtained being stored for use when required.

, The energy-efficiency in the electrolytic refining is dependent largely upon the perfection of the measures taken for preventing escape of heat. Theoretically almost no energy is required for the refining; but practically, in the absence of some other adequate source of heat, sufficient electrical energy must be expended to maintain the anode, the bath, and the cathode, in a fused condition, and consequently the amount of electrical energy which must be supplied is almost exactly the equivalent of the heat permitted to escape. After the heat insulation of the cell has been perfected to the maximum practicable extent, nothing further can be accomplished in limitation of the amount of heat escaping from a heated body of given dimensions, and with the minimum heat-loss the energy input required by the cell will also be a` minimum. ln the interests of power economy the cell should be operated at the lowest practicable voltage. Accordingly the electrolyte, which,

furnishes the major portions of the resistance, should be in as thin a layer as is permissible, and it has been found that a layer from 31A), to 411/2v inches thick is in general satisfactory. With a bath or electrolyte of any predetermined workable depth, the current density permissible varies between a lower limit which is sufficient to maintain the anode, the bat-h andthe cathode in a molten state, and an upper limit at which volatization of the bath is excessive or at which too large a proportion. of anode impurities goes into solution. These limits, with the various bath compositions which have been found praticable, are approximately 800 C. and 1100o C., respectively, with a preferable working temperature of about 950o C. The permissible lower limit of current density'also varies inversely with the dimensions of the cell, since the heat loss per'unit of volume in alarge cell is less than that in a small cell on account of the smaller rat-io of rheat-dissip'ating area to the volume.

In a cell having an active anode area of about 7 square feet, a current of about 8500 amperes has been found satisfactory in general. The preferred current density in a cell having the anode area mentioned is therefore about 1200 amperes per square foot. With the preferred current density mentioned, the total voltage between the terminals of the cell may be about 6 volts. Larger cells may be operated with 'lower current densities and at lower voltages, and by varying the size of the cell, the composition of the bath, the conductivity of-the bath, and the effectiveness of the heat insulation, 4the electrolytic refining step can be carried out with current densities between about 800 and about 1500 amperes per square foot of active anode area. In general the lower practicable limit of-voltage is about 3.5 volts and the upper limit is of course indefinite.

The layer of aluminum floating on the molten bath or electrolyte should be of sufficient expanse to touch the boundary crust of the cell around the entire perimeter thereof and should be thick enough to insure firm contact with this crust, in order to prevent or. minimize volatilization of the bath, which occurs to a greater or less extent at working temperatures and increases as the temperature rises. On account of the surface tension of molten aluminum the top layer should be 'of substantial depth, and, it is therefore `desirable to maintain a thickness of at least two inches.

So long as the aluminum content of the anode alloy is not much below 10" per cent, by weight, no difficultyA is ordinarily experil enced in obtaining a cathode metal having transferred, but by removing impoverished alloy and substituting fresh whenever the aluminum content has fallen too low the major portion of the latter metal can be obtained in very pure form.

The residual anode alloy from the electrolytic step or steps can now be treated to put the copper in good condition for reuse in the process. If the alloy is, low enough in iron and titanium so that the additional amount (of the latter metal or metals) which the alloy would receive in passing through step 2 of the process again, will not raise the iron-and-titanium content above that permissible in the electrolytic refining step, simple granulation of the alloyis usually all that is needed. For this purpose a blast of air or steam can be blown 'upon a stream of the molten alloy. In Fig. 4 we have illustrated the copper-recovery step in a diagrammatic manner. The molten-metal 50, poured from the vessel 51, issues in a stream from the funnel 52 into the path of a blast of air or steam from the valved pipe 53 and is blown into fragments which solidify and are caught by the hopper 54, whence they can be withdrawn through the chute 55 provided with a sliding gate 56. The liquid particles produced by the blast freeze too quickly to permit much oxidation, and hence the copper thus treated may contain considerable aluminum without suffering material loss of the latter. In other words, the electrolytic refining step may leave a substantial amount `of aluminum (and silicon also) in the anode cop- -per without much ifany being lost. If the residual anode copper contains too much `iron and titanium, or either, more or less of the same can be removed by the well known method of oxidation and slagging or by other convenient means before the metal is subjected to the air or steam blast. The oxidation can be effected in the vessel 51 by means of air (preferably preheated) delivered through one of the trunnions 57 to the pipe 58, whence it'issues through holes 59* inthe bottom of the vessel or converter and bubbles up through the metal therein. Of course in this method, residual aluminum present is oxidized with the iron and titanium and is removed with the slag. Hence it is desirable to remove as much of the aluminum as possible in the electrolytic refining step, so that the slag from the copper treatment can be thrown away without entailing serious loss.

The method of electrolytic refining described herein, with the preferred electrolyte, is claimed in our copending application Serial No. 608,285, filed December 21, 1922, referred to above; and the maintaining of the bath unsaturated with alumina, and the formation and maintenance of an insulating top-crust, is claimed in the copending appli- -in the copending application of William Hoopes, Serial No. 608,287, filed Decemberk lt is to be understood that the invention is not limited to details of procedure and apparatus herein specifically described but can be carried out in other Ways Without departure from its spirit as dened by the appending claims.

Vire claiml. A process of producing metallic aluminum, comprising treating aluminous material to remove ingredients thereof objectionable in the subsequent refining operation and leave a highly aluminous residue; smelting said aluminous residue in the presence of added material desirable in the said refining operation, to produce aluminum alloy; treating said alloy for further removal of objectionable material; and refining the treated alloy in a molten state to recover aluminum in metallic form therefrom.

2. A process of producing metallic aluminum, comprising smelting aluminousmaterial to remove more or less of its non-aluminous impurities and produce a highly aluminous slag, smelting said slag in the presence of copper in proportions to produce an alloy suitable for electrolytic refining, treating the alloy for further removal of impurities therefrom, and recovering metallic aluminum from the treated alloy by electrolytic refining in a molten state.

3. A process of producing metallic aluminum, comprising smelting aluminous material to remove impurities tending to impair the mobility of a molten aluminum alloy, and producing thereby a highly aluminous slag, smelting said `slag in the presence of a metal of higher boiling point than aluminum to produce an alloy of aluminum with such metal, treatingsaid alloy for further removal of objectionable impurities, and by clectrolytic treatment of the alloy in a molten state removing aluminum therefrom and collecting the same in metallic form.

4. A process of producing metallic alumi num, comprising treating aluminous material containing impurities under reducing conditions at a temperature belou7 that causing rapid reduction of the aluminous content of the material, to remove impurities tending to impair the mobility of aluminum alloy in a molten state, and producing thereby a highly aluminous slag containing such impurities in lessened amount; treating said slag in the presence of copper and a reducing agent at a temperature adequate to' reduce aluminous material, and producing thereby an alloy of aluminum and copper; collecting the aluminum-copper alloy and treating the same for removal of objectionable impurities, and electrolytically remov-4 tionable in the subsequent refining opera-y tion and leave a highly aluminous residue, smelting said aluminous residue in the presence of materialdesirable in the said refining operation, to produce aluminum alloy, treating said alloy for further removal of objectionable material, refining the treated alloy in the molten state to recover aluminum in metallic form therefrom, and treating the residual alloy to recover material or re-use in the smelting step of the process. i

6. A process of producing metallic aluminum, comprising smelting aluminous material to remove more or less of its nonaluminous impurities and produce a highly aluminous slag, smelting said slag in the presence of copper in proportions to produce an alloy suitable for electrolytic refining, treating the alloy for further removal of impurities therefrom, recovering metallic aluminum from the treated alloy by electrolytic rening in a molten state, and treating the residual alloy to fit the copper thereof for re-use in the process.

7. A process of producing metallic aluminum, comprising treating aluminous Inaterial to remove ingredients tending to raise the freezing point of aluminum-copper alloy, smelting the aluminous residue of said treatment in the presence of copper and added material adapted to increase the temperature range of mobility of the resulting aluminum-copper alloy, treating said alloy for removal of objectionable material, and refining the treated alloy in a molten state to recover aluminum in metallic form therefrom.

8. A process of producing metallic aluminum, comprising smelting aluminous material to reduce lnore or less of its non- -aluminous content and produce a highly aluminous slag, smelting said al .nniuous' slag in the presence of copper and silicon and producing an aluminum-copper-silicon alloy, treating the aluminum-coppcr-silicon alloy to remove therefrom material objectionable in eleetrolytic refining of the alloy, and refining the alloy eleetrolytically in a molten state to obtain metallic aluminum therefrom.

9. A process ot' producing metallic aluminum, comprising smelting aluminous .nia-

terial to reduce moreA or less of its nonaluminous content and produce a highly aluminous slag, smelting said aluminous slag in the presence of copper and silicon and producing an aluminum-copper-silicon alloy, treating the aluminum-copper-silicon alloy to remove the impurities therefrom, electrolyzing the aluminum-copper-silicon alloy in a molten state with a fused electrolyte to remove aluminum from the alloy and collecting the aluminum in metallic form, treating the residual alloy to recover copper therefrom, and returning the copper so recovered to the process for the production1 of the aluminum-coppersilicon alloy.

10. A process of producing metallic aluminum, comprising smelting aluminous material to reduce more or less of its nonaluminous content and produce a highly aluminous slag, smelting said aluminous slag in the p-resence 'of copper and silicon and producing an aluminum-copper-silicon alloy, treating the aluminum-copper-silcion alloy to remove therefrom material objectionable in `electrolytic treatment, and elecy trolyzing the aluminum-copper-silicon alloy in a molten state with a fused electrolyte to remove aluminum fro-m the alloy and collect the same in metallic form.

. 11.,A process of'produci-ng metallic alu'- minu'm, comprising treating aluminous ma? terial to decrease its non-aluminous content, smelting the treated material in the presence of copper and silicon and producing an aluminum-copper-silicon alloy, treating the aluminum-copper-silicon alloy to remove therefrom material objectionable in electrolytic treatment, and electrolyzing -the aluminum-copper-silicon alloy in a molten state with a fused electrolyte to obtain aluminum in metallic form from the alloy.

12. A process of producing metallic aluminum, comprising treating aluminous material to reduce separately, in the presence of different alloying metals, its non-alumi nous and aluminous ingredients and produce an aluminum alloy suitable for electrolytic refining; treating said alloy to' remove impurities therefrom; and electrolytically reiining the treated alloy in a-molten state to recover aluminum in metallic form therefrom. y v A '13. A process of producing metallic aluminum, comprising smelting aluminous material to reduce more or less of any iron and titanium oxids contained in the material, separating the metallic and nonmetallic products and-treating the latter un* der reducing conditions in the presence of copper and silicon for the production of an aluminum-cop-per-silicon alloy of low iron and titanium content, treating the aluminum-copper-silicon alloy to -remove nonmetallic material therefrom, and electrolyzing the aluminum-copper-silicon alloy in a molten state to obtain metallic aluminum from the alloy.

14. A process of producing metallic aluminum, comprising smelting s iliciousaluminous material in the presence of iron to reduce more or lessof any iron, titanium and silicon oxids contained in the material and produce an iron-silicon alloy and a highly aluminous non-metallic residue or slag of low iron and titanium content, treating the slag under reducing conditions in .the presence of copper and siliconv for the production of an alum-inum-copper-silicon alloy of low iron and 4titanium content, treating the aluminum-copper-silicon alloy to remove non-metallic material therefrom, and electrolyzing the aluminum-copper-silicon alloy in a molten state to obtain metallic aluminum from the alloy.

15. .A process of producing metallic aluminum, comprising treating aluminous material to produce separately, lin the presence of different nonaluminous metals, an alloy of low aluminum content and an allo-y of high aluminum content, treating the latter. alloy to remove material tending to impair the mobility of the alloy in a molten state, and electrolytically refining' the treated alloy in a molten state to obtain A metallic aluminum therefrom.

16. A process of producing metallic aluminum, comprising treating aluminous material to reduce separately, in the `presence of iron and in t e presence of copper land silicon, its non-aluminous' and yalumience of different non-aluminous metals, an

alloy of low aluminum content and an alloy of high aluminum content, treating the lat- -ter alloy to remove objectionable material,

electrolytically refining the treated alloy in a molten state to obtainmetallic aluminum therefrom, and returning to the process, for the production of the second-mentioned alloy, a metal'of the metallic residue of the electrol tic refining, whereby the said metal is emp oyed cyclically as a vehicle for the aluminum.

18. A process of producing metallic aluminum, comprising treating valuminous material to reduce separately, in .the presence of iron and in the presence of copper and silicon, .its non-aluminous and aluminous ingredients, and produce an aluminumcopper-silicon. alloy of low iron and a tita nium content, removing objectionable material from said alloy, treating the alloy electrolyticallyin a molten state to recover metallic aluminum therefrom, and returning to the process, for use in the roduction of the aluminum-copper-silicon a oy, residual copper from the electrolytic refining.

19. A process of producing metallic aluminum, comprising smelting in the pres- I ence of copper, aluminous material low in iron and titanium, `treating the resulting Y alloy to remove .objectionable material, and

thereafter electrolyzing the treated alloy in a molten state at a temperature below the freezing point of copper to recover metallic aluminum therefrom.

20. A process of producing metallic aluminum, comprising smelting in the presence of copper, aluminous material low in iron and `titaniumand adding thereto materialv effective to lower the freezing point of aluminum-copper alloy, collecting the resulting alloy, treating the same to remove non-metallic impurities, and electrolyticallyr refining the alloy in a molten state to obtain metallic aluminum therefrom.

21. A vprocess of producing metallic I aluminum, comprising smelting in the presence of copper aluminous material low in iron and titanium, supplying sllicon 1n amount adequate to produce an aluminum- .jcopper-silicon alloy mobile at the working temperature of a fluorid bath containing aluminum luorid, treatingv the aluminum- .c'opper-silicon alloy to remove materlal tending to impair the mobility of said bath,

and electrolytically impoverishing the treated alloy of its aluminum contentv in a molten state in said fluorid bath.

.22. A process of producing metallic aluminum, comprising smelting aluminous material low in iron and titanium in the presence of copperfblending silicon 4with the resulting roduct-to produce anl aluminnum-copper-si icon alioy mobile below the 'temperature o'f material volatilization of tionable material, and recovering aluminum from said alloy the `molten state.

24, In a process of producing rened aluminum, smelting aluminous material low in iron and titanium in the presence of copper to produce an aluminum-copper alloy low in iron and titanium and compounded to be mobile at the temperature of a fused electrolyte, and treating the alloy electrolytically in contact with such electrolyte to recover metallic aluminum from .the alloy.

25. In a process of producing refined aluminum from impure material, the steps comprising electrothermally producing with such material an aluminum-copper alloy suitable for electrolytic separation, treating the alloy to render it substantially free from entrained solid lmatter, and electrolytically removing and collecting aluminum from the alloy in a molten state. 26. In a process of producing refined aluminum from impure material, the steps comprising producing with such material an aluminum-copper alloy suitable for electrolytic separation, treating the alloy electrolytically as cathode with a fluorid electrolyte to remove objectionable materials, and electrolytically removing and collecting aluminum from the alloy in a molten state. 27. In a process of producing refined aluminum from impure material, the steps comprising producing with such material an aluminum-copper alloy suitable for electrolytic separation, treating the alloy mechanically to remove entrained solid matter and treating it electrolytically to render it substantially free from objectionable material,

and electrolytically removing and collecting.

aluminum from the alloy in a molten state.

28. In a process of producing refined aluminum from impure material, the steps comprising producing with such material an aluminum-copper alloy suitable for electrolytic separation, ltreating the alloy in a molten state with molten salts to remove objectionable impurities, and treating the alloy electrolytically in a molten sta-te to recover aluminum therefrom` 29. In a process ofproducing refined aluminum from impure material, the steps comprising producing with such material an aluminum-copper alloy adapted for electrolytic separation in a fused bath, treating the alloy in a molten state with molten fluorids to) remove material tending to impair the mobility of the bath at the temperature of such bath, and treating the alloy electrolytically in said fused bath to recover aluminum therefrom.

30. a process of producing metallic aluminum from impure material, producing with such material an aluminum-copper alloy of low iron and titanium content but containing silicon in substantial amount, treating the alloy to remove entrained solid material, and electrolyzing such alloy in a molten state with a fused electrolyte to remove aluminum from the' lloy.

3l. In a process of liriducing metallic aluminum from impure material, produc- .lng impure aluminum and silicon from thematerial by electrothermal reduction of the aluminous -and silicious constitutents thereof and such additional silicious materlal as lmay be needed, and With the addition of copper producing an aluminum-copper alloy of low iron and titanium content but' containing silicon in substantial amount; treating the alloy to remove entrained solid material;.and electrolyzing the said alloy in a molten state with a fused electrolyte to remove aluminum rom the alloy.

32; In a process' of producing metallic aluminum from impure material, treating:

'substances to remove silicon, iron and ti-` tanium, and product7 a highly aluminous slag of low iron and titanium content; treating the slag electrothermally and with the addition of silicon in suitable form producing v`aluminum-copper-silicon allo low' in iron and titanium; treating the al oy to remove;v entrained solid material; and eleotrolyzing the said alloy in a molten state to lremove aluminum therefrom.

34. In a processof producing metallic aluminum from impure material, treating electrothermally with suitable substances 'aluminous material containing silica, and iron and titanium, oxid, and producing an alloy containing silicon, iron, and titanium,

and a 'copper allow containing silicon and' a substantial'portion of the aluminum of the original material treating vthe alloy to re- 'move' entrained solid material; electrolyticallyremoving aluminum from the alloy; land treating'the alloy, after the removal of aluminum, to recover copper therefrom.

" 35. In a process for, producing metallic.v

aluminum from impure material containing alumina,`smelting the material in the pres ence of -iron to produce an'iron alloy containing: al substantial amount of any -iron and titanium present in said material and leave -a nonmetallic residue or slag of low iron and titanium content, but containing a substantial amount of the alumina, treating the saidresidue'to reduce aluminum-copper-.siliconalloy of ow` iron and titanium content, treating the alloy to remove entrained solid material, and electrolytically removing aluminum from a lower molten body of said .alloy as anode and depositing the aluminum so removed on an upper body of molten aluminum as cathode through an intermediate layer of fused electrolyte.

36. In a process of producing metallic aluminum from impure material containing alumina, smelting the material in the presence of iron to produce an iron alloy con taining a substantial amount of any iron and titanium present in said material, and

leave a nonmetallic residue or Slag of 10W iron and titanium content but containin a` substantial amount of the alumina, treating the said residue to produce aluminum-copper-silicon alloy ofloW iron and titanium content, treating the alloy to remove fen trained solid material, electrolytically re moving aluminum from a lower molten body of said alloy asanode and depositing the aluminum so removed on an upper body of molten aluminum as cathode through an intermediate layer of fused electrolyte, and returning to the process copper from the resid minum-copper-silicon alloy. i

37. In a process ofV producing metallic aluminum from impure material containing ual alloy, for the production: of the alu-l alumina and silica, s melting the material l electrothermally w1th'a subs`tance adapted to take up a substantial amount of any iron and titanium containedv in said material, to produce a nonmetallic mixture low in iron and titanium and containing a substantial amount of the alumina, treating the said mixture electrothermally with a .reducing agent in the presenceof opper .and silica to produce aluminum-copper-silicon alloy of low iron and titanium content, treating the alloy to! remove entrained solid 'imateriaL electrolytically removing aluminum from a lower molten body of said allyasanode and depositing the aluminum so removed on' an upper body of molten aluminum las cathode, through an intermediate body of fused electrolyte, and returning the copper of the impoverished anodealloy to the process, for

the production of th aluminum-copperl silicon alloy. l l

38. In a` process'of producing metallic aluminum from impure material containin alumina and silica,- smelting the materia electrothermally in the presence of iron to produce a silicon-iron alloy and a nonmetallic residue or slag of low iron and titanium content and containing a substantial amount of the alumina; treating the said residue electrothermally with a-reducing agent in the presence of copper and silica to produce aluminum-copper-silicon alloy of lowiron and titanium content, treating thealloy to remove entrained sol id material, electrolytically removing aluminum from a lower molten body of said alloy vas ano de and depositing the aluminum so removed on'an upper'body of molten aluminum as cathode through an agent and a heavy metal to reduce and precipitate undesired portions of said impurities and produce a non-metallic slag rich in alumina, reducing saidslag electrothermallyI in the presence of a metal of higher boiling n point and greater density free from impuri ties objectionable in electrolytic refining, recovering the resulting aluminum alloy, 1m-

poverishing said alloy by electrolytic alo-y straction of aluminum, recovering said metal of higher boiling point and greater density from said impoverished alloy and returning said recovered metal for re-use in said process.

40. In a process of producing metallic aluminum from impure material, the steps comprising producing from such material an aluminum-copper alloy of lo7 iron and titanium content, and treating said alloy to' remove nonmetallic impurities therefrom.

41. In a process of producing metallic aluminum from impure material, the steps comprising producing impure aluminum and silicon from the material by electrothermal reduction of the aluminous and silicious con stituents thereof and such additional silicious material as may be` needed, and with the addition of copper producing an `alumi` num-copper alloy of low iron and titanium content but containing silicon in substantial amount; and treating said alloy to remove entrained solid material.

42. In; a process of producing metallic aluminumggfrom impure' material, the steps comprising treating the material electrothermally with' suitable substances to remove silicon, iron, and titanium, and produce a highly aluminousslag low in iron and titanium; utilizing the slag for the electrothermal production of aluminum-coppersilicon alloy of low iron and titanium content; and treating the alloy to remove entrained solid material. '(43. In a process for producing metallic aluminum from impure materials, the steps comprising treating the material electrothermally with suitable substances to produce-aluminum-copper alloy, and treating the alloy to remove entrained solid material.

44. In a process for producing metallic aluminum from 'impure materials, the steps comprising treating o aluminous material elect-rothermally to separate iron and titanium therefrom, and after such separation treating the material electrothermally with copper to produce aluminum-copper alloy low in iron and titanium.` 45. In aprocess for producing metallic aluminum from impure materials, the step comprising producing by elect-rotliermal treatment of such material an aluminumcopper alloy low in iron and titanium.

. 46. In a process for producing metallic aluminum from impure materials, the step comprising producing from such material,

an aluminumcopper alloy .10W in iron and titanium.

In testimony whereof we hereto aiix our signatures.

WILLIAM HOOPES. FRANCIS C. FRARY. JUNIUS D. EDWARDS. 

